FEATURED WORK
ASB HEAD OFFICE
Location: Auckland
Product: Smart Tray Double Locked Tapered Standing Seam Tray Roofing
Surface: 1600 sqm
Architect: BVN Architecture and Jasmax
Main Contractor: Fletcher Construction​
Located on the corner of Jellicoe and Halsey streets and looking directly over the viaduct itself, the feature roof was a challenge to conventional tray roof design/installation and is destined to change the local skyline for many years to come.
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To achieve the free-flowing lines associated with a natural volcanic shape, the designers opted for faceted roofing sheets for the corners, as well as for the concave and convex surfaces of the kidney-shaped northern aspect. This gives the illusion of soft curved corners. The company’s initial concerns about working on a 60° roof pitch proved accurate and extreme care had to be taken while working on these tricky surfaces.
Initially the team from Architectural Metalformers had planned to work from CAD drawings but minor “as built” variations resulted in the team resorting to tape measures, string lines and a notepad. Good old trigonometry functions were essential to come up with a quick, efficient and accurate system for transferring the details back to the factory for production into the Smart Tray sheets, each with its own unique sequenced number relating back to its exact spot on the roof.
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To efficiently manufacture the tapered panels we made a significant investment in new machinery from Europe, including specific equipment to install the horizontal expansion joint to each panel.
BAY VIEW HOUSE
Location: Auckland
Products: Smart Tray Lock Seam Roofing; Smart Tray Metal Cladding; Smart Sheet TIG Welded Aluminium Cappings and Lock Seam Tray Roofing
Medium: Aluminium – Euramax Pre Painted, Colorcote Pre Painted + 1.6mm Powdercoated
Surface: Various
Architect: Robin O’Donnell Architects
Main Contractor: Good Bros Construction
This property enjoys spectacular views of the beach and the wider harbour to the north and east. To satisfy the brief for a modern family home that made the most of the view on a restricted narrow site, the property was split over three levels replacing an existing home that was demolished to make way for the new build.
Architectural Metalformers was contracted to install Aluminium Lock Seam roofing and barcode wall cladding which was chosen for appearance and durability and the need to integrate the new building into a busy setting in a coastal location.
HOUSE OF THE YEAR
GOLD AWARD WINNERS 2018
GOLD AWARD- NEW HOUSE OVER 2 MILLION
Product: Smart Tray Standing Seam Roofing
Medium: Euramax Grey Black
Main Contractor: Allan Wallace Builders
This is another award winning build for Allan Wallace, showcasing 630sqm of country retreat in Kumeu and worthy of its Gold award at the recent Registered Master Builders House of the Year 2018.
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We are proud to be part of Allan’s team of contractors providing quality roofing and custom guttering to this home.
GOLD AWARD- RENOVATION OVER 1 MILLION
Product: 25mm Smart Tray Standing Seam Wall Cladding
Medium: VM Anthra Zinc Plus
Architect: Shanahan Architects
Main Contractor: TP Builders
The front facade remains in tune with the streetscape. Defined by a black zinc-clad pavilion, the modern extension accommodates luxurious new living and kitchen areas.
Congratulations to TP Builders on winning Gold on this exceptional renovation. Far from a simple makeover, the four-bedroom, three-bathroom masterpiece is a bold reflection of the owners’ interest in design, art and architecture.
SCOTT BASE
RESTORING THE HILARY HUT
Location: Scott Base, Ross Island, Antarctica
Product: Smart Tray Custom Height Standing Seam
Medium: 0.9mm Alumigard
Surface: 79m2
Architect: Cheshire Architects
Main Contractor: Antarctica Heritage Trust
The hut is an important link to Hillary’s famous tractor trip to the South Pole and was built under his guidance by his team in 1957. Under guidance from conservation architect, Pip Cheshire of Cheshire Architects, Hillary’s hut has been painstakingly restored, ensuring the preservation of precious artefacts from the era of early exploration.
Well known to architects for his knowledge and skill in the secret fix, European style of roofing, Mike Burgess from Architectural Metalformers was the installer of choice for the final stage of the restoration project. Mike can attest to the significance and privilege of being assigned for this assignment at the South Pole.
As Project Manager, it was agreed that Mike’s time and all services required to complete the task including provision and transport of materials and accessories, manufacturing time and technical input would be donated to the trust for the project.
“Assisting me on the re-roof was Antarctic Youth Ambassador from the Sir Peter Blake Trust, engineer Chris Ansin. We would check the weather at our daily toolbox meeting and layer our clothing accordingly right down to leggings, footwear, boots, buffer goggles, beanies and gloves”.
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“There were days when I had to sacrifice being warm to achieve the perfection the job required. As an example, although we had gloves they would often be too restrictive, and I would work with bare hands for a limited amount of time before they started to freeze. Then I would crack hand-warming gel packs and keep them in my pockets to warm up my hands as required”.
Mike seized this once in a lifetime opportunity to immerse himself in the Antarctic experience during his 13 days on Scott Base, six of which were taken up with completing the hut. Twenty-four hours of daylight meant evenings could be spent exploring beyond the base.
It was all about absorbing what life must have been like for those early pioneers. Adding to Mike’s experience, Nigel Watson, chairman of the Antarctic Heritage Trust, accompanied Mike on a tour of all the expedition huts including the original Discovery hut for a privileged view of the historical artefacts – mutton carcases still hanging, biscuits in a remarkable state of preservation – even food still perfectly preserved on the stove top from the day the last inhabitants ventured out into the cold and never returned.
Congratulations to the Antarctica Heritage Trust for preserving this historic building for future generations. Architectural Metalformers are thrilled to be a part of the process.
AUCKLAND WAR MEMORIAL MUSEUM
Location: Auckland
Product: Smart Tray Custom Made Wave Dome Roofing
Medium: Copper
Surface: 980 sqm
Architect: Noel Lane and Peddle Thorp Architects
Main Contractor: Hawkins Construction
Architectural Metalformers Ltd created the “wave” dome for the Grand Atrium at the Auckland War Memorial Museum. The undulating copper roof and matching gutter is a unique achievement for our team. Most of the copper work was completed in February and March 2007, including 96 lineal metres of copper full half round guttering and 5mm brass brackets.
With only four of the 1760 copper panels on the Grand Atrium dome being the same measurement, the scale and complex detailing of the dome was heavily reliant on a CAD software system offering 3D imaging. The Architectural Metalformers team also devised innovative and number eight wire solutions for the different radii required for each panel.
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Meticulous attention to detail, provision of product samples across the entire job and exhaustive hours of plotting on the CAD software has resulted in a dome the company is proud to call its own.
VODAFONE HEAD OFFICE
Location: Auckland Viaduct
Product: Custom Made Splayed Roofing
Medium: Copper
Surface: 1030 sqm
Architect: Jasmax
Main Contractor: Watts and Hughes Construction
Architectural Metalformers created the splayed tray roof for the Auckland Vodafone Head Office on Auckland’s Viaduct. This result was achieved by using a joining process especially developed by our in-house technical team to achieve an effect that spanned 14 metres at its longest point.
2018 WINNER
NZIA AUCKLAND ARCHITECTURE AWARD
Location: Auckland
Products: Smart Tray Lockseam Roofing and Cladding; Smart Rain Spouting, Downpipes and Internal Gutters
Medium: Euramax Pre Painted Aluminium – ‘Schist’
Surface: Various
Architect: Robin O’Donnell Architects
Main Contractor: Good Bros Construction
This property enjoys spectacular views of the Harbour Bridge, and Westhaven Marina, appropriate for this family with its strong nautical links. The site is typical of this location at only 324m² with traditional timber villas and newer houses tightly arranged on small sites.
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The brief was for a modern family home sympathetic in overall form to its historic context but with minimalist detailing to clearly articulate it as a new building.
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Materials have been selected on the basis of appearance and durability and the Council imposed requirement to go some way to integrate the new building into its historic context. However, the tray roof cladding wrapping over the building and folding down the southern elevation clearly identify the building as new. Interior finishes use a refined palette of polished concrete, walnut and steel pallete to compliment the sculptural qualities inherent in the gable roof forms expressed throughout.
AOTEA CENTRE
Location: Auckland
Products: Flatlock panel on Extruded Rail System
Medium: Custom Coloured Textured German Stainless Steel
Surface: 3000 sqm
Architect: Stephenson & Turner, Ignite Architects
Main Contractor: New Zealand Strong
In October 2018, construction began on the exterior refurbishment of Auckland’s renowned Aotea Centre, a central fixture in the CBD’s architectural character since the early 1990s, but a building whose age and end-of-life materials were beginning to cause wide-spread water ingress issues.
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While official work began in 2018, planning for the project went much further back. In the early 2010s, Auckland Council’s cultural arm Regional Facilities Auckland (now known as Auckland Unlimited) brought on architecture and engineering firm Stephenson & Turner (S&T) as contractors for the project.
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Not long after, S&T engaged Architectural Metalformers (AMF) – a New Zealand-owned company that specialises in architectural roofing, cladding and sheet metal solutions.
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“We were asked to come on board and assist with what was a very broad concept at that stage – of recladding the existing precast panel at the Aotea Centre,” says Mike Burgess, Project Manager at Architectural Metalformers.
S&T approached the company when the idea for an exterior cladding system comprising metal panels was solidified. Working with the S&T team, Architectural Metalformers provided guidance on the appropriate cladding system.
In January 2019, Architectural Metalformers began the internal cladding process. This included installation of all diagonal lines for the new rail system — which proved difficult over an exposed aggregate precast panel.
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Three months later, work stalled due to internal structure issues. This halted work on the project for the rest of the year.
In January 2020 AMF restarted onsite, with a small mobile factory assisting two teams of three to install panels to separate wall faces. Mike says the installation was difficult due to the deletion of the plywood, as well as the sheer size and geometry of the building — however the finished result is something the company is “extremely proud of”.
In November 2021 AMF installed the last of over 3,500 handmade panels.
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With Architectural Metalformers work on the building 100% completed, Mike says that despite a long and complex process, which started over a decade ago, Architectural Metalformers are ecstatic with the result.
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“In the past, we’ve worked on multiple heritage projects – for example, the iconic roof of the Auckland War Memorial Museum,” says Mike. “Many of our team have been lucky enough to work on projects that will stand the test of time. We can look back on them with pride at the workmanship and craft involved in complex work and it would be great for the next generation of staff at Architectural Metalformers to also have something to look back at and be proud of contributing to."
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“From the outset, that’s how I viewed the Aotea Centre.”